High Performance Inverter
Thank you for purchasing our multifunction FRENIC-Ace series of inverters.
• This product is designed to drive a three-phase motor under variable speed control. Read through
this instruction manual and become familiar with the handling procedure for correct use.
• Improper handling might result in incorrect operation, a short life, or even a failure of this product as
well as the motor.
Copyright © 2013 Fuji Electric Co., Ltd.
All rights reserved.
No part of this publication may be reproduced or copied without prior
written permission from Fuji Electric Co., Ltd.
All products and company names mentioned in this manual are trademarks
or registered trademarks of their respective holders.
The information contained herein is subject to change without prior notice
for improvement.
Thank you for purchasing our multifunction FRENIC-Ace series of inverters. This product is
designed to drive a three-phase induction motor under variable speed control.
This manual provides all the information on the FRENIC-Ace series of inverters including its
operating procedure and selection of peripheral equipment. Before use, carefully read this manual
for proper use. Improper handling might result in incorrect operation, a short life, or even a failure
of this product as well as the motor.
The table below lists the other materials related to the use of the FRENIC-Ace. Read them in
conjunction with this manual as necessary.
Name Material
No.
Description
Catalog 24A1-E-0042
Product scope, features, specifications, external drawings,
and options of the product
FRENIC-Ace User's Manual
24A7-E-0043
Product details control block diagrams, specifications, and
external dimensions
RS-485 Communication User's
Manual
24A7-E-0021*
Overview of functions implemented by using FRENIC-Ace
RS-485 communications facility, its communications
specifications, Modbus RTU/Fuji general-purpose inverter
protocol, function codes and related data formats
*Available soon
Chapter 1 BEFORE USE
1.1 Acceptance
Inspection (Nameplates and Inverter Type) ··· 1-1
1.2
External View and Terminal Blocks ··· 1-3
1.3
Precautions for Using Inverters··· 1-4
1.3.1 Usage
environment ··· 1-4
1.3.2 Storage
environment ··· 1-6
[ 1 ] Temporary storage...1-6
[ 2 ] Long-term storage...1-6
Chapter 2 INSTALLATION AND WIRRING
2.1 Installation··· 2-1
2.2 Wiring ··· 2-3
2.2.1 Basic
connection diagram··· 2-3
2.2.2
Removal and attachment of the front cover and wiring guide ··· 2-6
2.2.3 Precautions
for wiring ··· 2-7
2.2.4
Precautions for long wiring (between inverter and motor) ··· 2-9
2.2.5 Main
circuit terminals ··· 2-11
[ 1 ] Screw specifications and recommended wire size (main circuit terminals) ...2-11
[ 2 ] Terminal layout diagram (main circuit terminal) ...2-24
[ 3 ] Description of terminal functions (main circuit terminal) ...2-24
2.2.6
Control circuit terminals (common to all models)··· 2-29
[ 1 ] Screw specifications and recommended wire size (control circuit terminal)...2-29
[ 2 ] Terminal layout diagram (control circuit terminal) ...2-29
[ 3 ] Description of terminal functions (control circuit terminal) ...2-30
2.2.7 Switching
connector ··· 2-37
2.2.8 Operating
various switches ··· 2-39
Chapter 3 OPERATION USING THE KEYPAD
3.1
Names and Functions of Keypad Components ··· 3-1
3.2
Overview of Operation Modes ··· 3-3
Chapter 4 TEST RUN PROCEDURE
4.1
Test Run Procedure Flowchart ··· 4-1
4.2
Checking Prior to Powering On··· 4-2
4.3
Powering ON and Checking··· 4-3
4.4
Switching the Applicable Motor Rank (ND, HD, HND and HHD Modes) ··· 4-3
Chapter 5 FUNCTION CODES
5.1
Function Code Overview ··· 5-1
5.2
Function Code Table ··· 5-1
5.2.1 Supplementary
note ··· 5-1
5.2.2 Function
code table ··· 5-3
7.3 Periodic
Inspection ··· 7-3
[ 1 ] Periodic inspection 1--Before the inverter is powered ON or after it stops running .... 7-3
[ 2 ] Periodic inspection 2--When the inverter is ON or it is running ... 7-4
7.4 List of Periodic Replacement Parts ··· 7-5
7.5 Measurement of Electrical Amounts in Main Circuit ··· 7-6
7.6 Insulation Test ··· 7-7
7.7 Inquiries about Product and Guarantee ··· 7-8
7.7.1 When making an inquiry ··· 7-8
7.7.2 Product
warranty ··· 7-8
[ 1 ] Free of charge warranty period and warranty range ... 7-8
[ 2 ] Exclusion of liability for loss of opportunity, etc ... 7-9
[ 3 ] Repair period after production stop, spare parts supply period (holding period) ... 7-9
[ 4 ] Transfer rights ... 7-9
[ 5 ] Service contents ... 7-9
[ 6 ] Applicable scope of service ... 7-9
Appendix H Conformity with Standards
H.1 Compliance with European Standards (
) ··· Appendix-1
H.1.1 Compliance with EMC standards ··· Appendix-1
H.1.2 Compliance with the low voltage directive in the EU ··· Appendix-3
Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance
and inspection. Ensure you have sound knowledge of the device and familiarize yourself with all safety information
and precautions before proceeding to operate the inverter.
Safety precautions are classified into the following two categories in this manual.
Failure to heed the information indicated by this symbol may lead to dangerous
conditions, possibly resulting in death or serious bodily injuries.
Failure to heed the information indicated by this symbol may lead to dangerous
conditions, possibly resulting in minor or light bodily injuries and/or substantial
property damage.
Failure to heed the information contained under the CAUTION title can also result in serious consequences. These
safety precautions are of utmost importance and must be observed at all times.
Application
• The FRENIC-Ace is designed to drive a three-phase induction motor. Do not use it for single-phase motors
or for other purposes.
Fire or an accident could occur.
• The FRENIC-Ace may not be used for a life-support system or other purposes directly related to the human
safety.
• Though the FRENIC-Ace is manufactured under strict quality control, install safety devices for applications
where serious accidents or property damages are foreseen in relation to the failure of it.
An accident could occur.
Installation
• Install the inverter on a base made of metal or other non-flammable material.
Otherwise, a fire could occur.
• Do not place flammable object nearby.
Doing so could cause fire.
• Inverters FRN0085E2S-4
or above, whose protective structure is IP00, involve a possibility that a human
body may touch the live conductors of the main circuit terminal block. Inverters to which an optional DC
reactor is connected also involve the same. Install such inverters in an inaccessible place.
Otherwise, electric shock or injuries could occur.
• Do not support the inverter by its front cover during transportation.
Doing so could cause a drop of the inverter and injuries.
• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the
inverter or from accumulating on the heat sink.
• When changing the positions of the top and bottom mounting bases, use only the specified screws.
Otherwise, a fire or an accident might result.
• Do not install or operate an inverter that is damaged or lacking parts.
• If no zero-phase current (earth leakage current) detective device such as a ground-fault relay is installed in
the upstream power supply line in order to avoid the entire power supply system's shutdown undesirable to
factory operation, install a residual-current-operated protective device (RCD)/earth leakage circuit breaker
(ELCB) individually to inverters to break the individual inverter power supply lines only.
Otherwise, a fire could occur.
• When wiring the inverter to the power source, insert a recommended molded case circuit breaker (MCCB) or
residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent
protection) in the path of each pair of power lines to inverters. Use the recommended devices within the
recommended current capacity.
• Use wires in the specified size.
• Tighten terminals with specified torque.
Otherwise, a fire could occur.
• When there is more than one combination of an inverter and motor, do not use a multicore cable for the
purpose of handling their wirings together.
• Do not connect a surge killer to the inverter's output (secondary) circuit.
Doing so could cause a fire.
• Be sure to connect an optional DC reactor (DCR) when the capacity of the power supply transformer exceeds
500 kVA and is 10 times or more the inverter rated capacity.
Otherwise, a fire could occur.
• Ground the inverter in compliance with the national or local electric code.
• Be sure to ground the inverter's grounding terminals G.
Otherwise, an electric shock or a fire could occur.
• Qualified electricians should carry out wiring.
• Be sure to perform wiring after turning the power OFF.
Otherwise, an electric shock could occur.
• Be sure to perform wiring after installing the inverter unit.
Otherwise, an electric shock or injuries could occur.
• Ensure that the number of input phases and the rated voltage of the product match the number of phases and
the voltage of the AC power supply to which the product is to be connected.
Otherwise, a fire or an accident could occur.
• Do not connect the power supply wires to output terminals (U, V, and W).
• When connecting a DC braking resistor (DBR), never connect it to terminals other than terminals P(+) and
DB.
Doing so could cause fire or an accident.
• In general, sheaths of the control signal wires are not specifically designed to withstand a high voltage (i.e.,
reinforced insulation is not applied). Therefore, if a control signal wire comes into direct contact with a live
conductor of the main circuit, the insulation of the sheath might break down, which would expose the signal
wire to a high voltage of the main circuit. Make sure that the control signal wires will not come into contact with
live conductors of the main circuit.
Doing so could cause an accident or an electric shock.
• Before changing the switches or touching the control circuit terminal symbol plate,
turn OFF the power and
wait at least five minutes for inverters FRN0072E2S-4
or below, or at least ten minutes for inverters
FRN0085E2S-4
or above
. Make sure that the LED monitor and charging lamp are turned OFF. Further,
make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+)
and N(-) has dropped to the safe level (+25 VDC or below).
• Be sure to mount the front cover before turning the power ON. Do not remove the cover when the inverter
power is ON.
Otherwise, an electric shock could occur.
• Do not operate switches with wet hands.
Doing so could cause electric shock.
• If the auto-reset function has been selected, the inverter may automatically restart and drive the motor
depending on the cause of tripping. Design the machinery or equipment so that human safety is ensured at
the time of restarting.
Otherwise, an accident could occur.
• If the stall prevention function (current limiter), automatic deceleration (anti-regenerative control), or
overload prevention control has been selected, the inverter may operate with acceleration/deceleration or
frequency different from the commanded ones. Design the machine so that safety is ensured even in such
cases.
• The key on the keypad is effective only when the keypad operation is enabled with function code F02 (=
0, 2 or 3). When the keypad operation is disabled, prepare an emergency stop switch separately for safe
operations.
Switching the run command source from keypad (local) to external equipment (remote) by turning ON the
"Enable communications link" command
LE
disables the
key. To enable the
key for an emergency
stop, select the STOP key priority with function code H96 (= 1 or 3).
• If any of the protective functions have been activated, first remove the cause. Then, after checking that the
all run commands are set to OFF, release the alarm. If the alarm is released while any run commands are set
to ON, the inverter may supply the power to the motor, running the motor.
Otherwise, an accident could occur.
• If you enable the "Restart mode after momentary power failure" (Function code F14 = 3 to 5), then the
inverter automatically restarts running the motor when the power is recovered.
Design the machinery or equipment so that human safety is ensured after restarting.
• If the user configures the function codes wrongly without completely understanding this manual, the motor
may rotate with a torque or at a speed not permitted for the machine.
• Starting auto-tuning involves motor rotation. Sufficiently check that motor rotation brings no danger
beforehand.
An accident or injuries could occur.
• Even if the inverter has interrupted power to the motor, if the voltage is applied to the main circuit input
terminals L1/R, L2/S and L3/T, voltage may be output to inverter output terminals U, V, and W.
• Even if the motor is stopped due to DC braking or preliminary excitation, voltage is output to inverter output
terminals U, V, and W.
An electric shock may occur.
• The inverter can easily accept high-speed operation. When changing the speed setting, carefully check the
specifications of motors or equipment beforehand.
Otherwise, injuries could occur.
• Do not touch the heat sink and braking resistor because they become very hot.
Doing so could cause burns.
• The DC brake function of the inverter does not provide any holding mechanism.
Injuries could occur.
• Ensure safety before modifying the function code settings.
Run commands (e.g., "Run forward"
FWD
), stop commands (e.g., "Coast to a stop"
BX
), and frequency
change commands can be assigned to digital input terminals. Depending upon the assignment states of
those terminals, modifying the function code setting may cause a sudden motor start or an abrupt change in
speed.
• Before proceeding to the maintenance/inspection jobs,
turn OFF the power and wait at least five minutes
for inverters FRN0072E2S-4
or below, or at least ten minutes for inverters FRN0085E2S-4
or
above
. Make sure that the LED monitor and charging lamp are turned OFF. Further, make sure, using a
multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has
dropped to the safe level (+25 VDC or below).
Otherwise, an electric shock could occur.
• Maintenance, inspection, and parts replacement should be made only by qualified persons.
• Take off the watch, rings and other metallic objects before starting work.
• Use insulated tools.
Otherwise, an electric shock or injuries could occur.
• Never modify the inverter.
Doing so could cause an electric shock or injuries.
Disposal
• Treat the inverter as an industrial waste when disposing of it.
Otherwise injuries could occur.
GENERAL PRECAUTIONS
Drawings in this manual may be illustrated without covers or safety shields for explanation of detail parts. Restore
the covers and shields in the original state and observe the description in the manual before starting operation.
Icons
The following icons are used throughout this manual.
This icon indicates information which, if not heeded, can result in the inverter not operating to full efficiency,
as well as information concerning incorrect operations and settings which can result in accidents.
This icon indicates information that can prove handy when performing certain settings or operations.
This icon indicates a reference to more detailed information.
Chapter 1 BEFORE USE
1.1 Acceptance Inspection (Nameplates and Inverter Type)
Unpack the package and check the following:
(1) An inverter and the following accessories are contained in the package.
Accessories - DC reactor (for ND-mode inverters of FRN0139E2S-4
or above, HD-/HND-mode inverters
of FRN0168E2S-4
or above, and HHD-mode inverters of FRN0203E2S-4
or above)
(Not bundled with the FRN****E2S-4C)
- Keypad rear cover (with three screws for securing the keypad)
- Instruction manual
- CD-ROM (containing the FRENIC-Ace User's Manual)
(2) The inverter has not been damaged during transportation—there should be no dents or parts missing.
(3) The inverter is the type you ordered. You can check the type and specifications on the main nameplate. (The
main and sub nameplates are attached to the inverter as shown on Figure 1.2-1.)
(a) Main Nameplate
(b) Sub Nameplate
Figure 1.1-1 Nameplates
The FRENIC-Ace is available in four different drive modes--ND (Normal Duty), HD (Heavy Duty), HND
(High, Normal Duty) and HHD (High, Heavy Duty). One of these modes should be selected to match the
load property of your system. Specifications in each mode are printed on the main nameplate.
ND mode
: Designed for general load applications.
Overload capability: 120% for 1 min.
HD mode
: Designed for heavy duty load applications.
Overload capability: 150% for 1 min.
HND mode : Designed for general load applications.
Overload capability: 120% for 1 min.
HHD mode : Designed for heavy duty load applications.
Overload capability: 150% for 1 min. and 200% for 0.5 s.
SOURCE
: Number of input phases (three-phase: 3PH), input voltage, input frequency, input current
OUTPUT
: Number of output phases, rated output voltage, output frequency range, rated output
capacity, rated output current, and overload capability
SCCR
: Short-circuit capacity
MASS
: Mass of the inverter in kilogram
SER. No.
: Product number
6 8 A 1 2 3 A 0 5 7 9 E BB 6 0 1
Production week
This indicates the week number that is numbered
from 1st week of January.
The 1st week of January is indicated as '01'.
Production year: Last digit of year
Product version
If you suspect the product is not working properly or if you have any questions about your product, contact your
Fuji Electric representative.
1.2 External View and Terminal Blocks
(1) Outside and inside views
(a) FRN0072E2S-4
(b)
FRN0203E2S-4
Figure 1.2-1 Outside and Inside Views of Inverters
(2) Warning plates and label
Cooling fans
Main nameplate
Keypad
Front cover
Warning plate
Front cover
Control circuit terminal block
Main circuit
terminal block
Wiring guide
Front cover
mounting screw
Cooling fans
Mounting base
Keypad
Front cover
Front cover
Warning plate
Main nameplate
Main circuit
terminal block
Warning label
Keypad enclosure
(openable)
Internal air circulation fan
Control circuit
terminal block
1.3 Precautions for Using Inverters
This section provides precautions in introducing inverters, e.g. precautions for installation environment, power
supply lines, wiring, and connection to peripheral equipment. Be sure to observe those precautions.
1.3.1 Usage environment
Install the inverter in an environment that satisfies the requirements listed in Table 1.3-1.
Table 1.3-1 Usage Environment
Item
Specifications
Site location
Indoors
Ambient temperature
-10 to +50
°
C (14 to 122
°
F)
(Note 1)
Relative humidity
5 to 95% RH (No condensation)
Atmosphere
The inverter must not be exposed to dust, direct sunlight, corrosive gases,
flammable gases, oil mist, vapor or water drops.
Pollution degree 2 (IEC60664-1)
(Note 2)
The atmosphere can contain a small amount of salt. (0.01 mg/cm
2or less per year)
The inverter must not be subjected to sudden changes in temperature that will
cause condensation to form.
Altitude
1,000 m (3,300 ft) max. (Note 3)
Atmospheric pressure
86 to 106 kPa
Vibration
FRN0203E2S-4
or below
3 mm (Max. amplitude) 2 to less than 9 Hz
9.8 m/s
29 to less than 20 Hz
2 m/s
220 to less than 55 Hz
1 m/s
255 to less than 200 Hz
(Note 1) When inverters are mounted side-by-side without any clearance between them (FRN0072E2S-4
or below), the
ambient temperature should be within the range from -10 to +40
°
C.
(Note 2) Do not install the inverter in an environment where it may be exposed to lint, cotton waste or moist dust or dirt which
will clog the heat sink of the inverter. If the inverter is to be used in such an environment, install it in a dustproof panel of your
system.
(Note 3) If you use the inverter in an altitude above 1,000 m (3,300 ft), you should apply an output current derating factor as
listed in Table 1.3-2.
Table 1.3-2 Output Current Derating Factor in Relation to Altitude
Altitude
Output current derating
factor
1,000 m or lower (3,300 ft or lower)
1.00
1,000 to 1500 m (3,300 to 4,900 ft)
0.97
1,500 to 2,000 m (4,900 to 6,600 ft)
0.95
2,000 to 2,500 m (6,600 to 8,200 ft)
0.91
2,500 to 3,000 m (8,200 to 9,800 ft)
0.88
Fuji Electric strongly recommends installing inverters in a panel for safety reasons, in particular, when installing
the ones whose enclosure rating is IP00.
When installing the inverter in a place out of the specified environmental requirements, it is necessary to derate
the inverter or consider the panel engineering design suitable for the special environment or the panel installation
location. For details, refer to the Fuji Electric technical information "Engineering Design of Panels" or consult your
Fuji Electric representative.
The special environments listed below require using the specially designed panel or considering the panel
installation location.
Environments
Possible problems
Sample measures
Applications
Highly
concentrated
sulfidizing gas or
other corrosive
gases
Corrosive gases cause
parts inside the inverter to
corrode, resulting in an
inverter malfunction.
Any of the following measures
may be necessary.
- Mount the inverter in a sealed
panel with IP6X or air-purge
mechanism.
- Place the panel in a room
free from influence of the
gases.
Paper manufacturing,
sewage disposal, sludge
treatment, tire
manufacturing, gypsum
manufacturing, metal
processing, and a
particular process in
textile factories.
A lot of conductive
dust or foreign
material (e.g.,
metal powders or
shavings, carbon
fibers, or carbon
dust)
Entry of conductive dust
into the inverter causes a
short circuit.
Any of the following measures
may be necessary.
- Mount the inverter in a sealed
panel.
- Place the panel in a room
free from influence of the
conductive dust.
Wiredrawing machines,
metal processing,
extruding machines,
printing presses,
combustors, and
industrial waste
treatment.
A lot of fibrous or
paper dust
Fibrous or paper dust
accumulated on the heat
sink lowers the cooing
effect.
Entry of dust into the
inverter causes the
electronic circuitry to
malfunction.
Any of the following measures
may be necessary.
- Mount the inverter in a sealed
panel that shuts out dust.
- Ensure a maintenance space
for periodical cleaning of the
heat sink in panel
engineering design.
- Employ external cooling
when mounting the inverter in
a panel for easy maintenance
and perform periodical
maintenance.
Textile manufacturing
and paper
manufacturing.
High humidity or
dew condensation
In an environment where
a humidifier is used or
where the air conditioner
is not equipped with a
dehumidifier, high
humidity or dew
condensation results,
which causes a
short-circuiting or
malfunction of electronic
circuitry inside the
inverter.
- Put a heating module such as
a space heater in the panel.
Outdoor installation.
Film manufacturing line,
pumps and food
processing.
Vibration or shock
exceeding the
specified level
If a large vibration or
shock exceeding the
specified level is applied
to the inverter, for
example, due to a carrier
running on seam joints of
rails or blasting at a
construction site, the
inverter structure gets
damaged.
- Insert shock-absorbing
materials between the
mounting base of the inverter
and the panel for safe
mounting.
Installation of an inverter
panel on a carrier or
self-propelled machine.
Ventilating fan at a
construction site or a
press machine.
1.3.2 Storage environment
The storage environment in which the inverter should be stored after purchase differs from the usage environment.
Store the inverter in an environment that satisfies the requirements listed below.
[ 1 ] Temporary storage
Table 1.3-3 Storage and Transport Environments
Item
Specifications
Storage temperature
*
1During transport:
-25 to +70
°
C (-13 to +158
°
F)
Places not subjected to abrupt temperature
changes or condensation or freezing
During storage: -25 to +65
°
C (-13 to +153
°
F)
Relative humidity
5 to 95% RH
*
2Atmosphere
The inverter must not be exposed to dust, direct sunlight, corrosive or flammable gases, oil
mist, vapor, water drops or vibration. The atmosphere must contain only a low level of salt.
(0.01 mg/cm
2or less per year)
Atmospheric pressure
86 to 106 kPa (during storage)
70 to 106 kPa (during transportation)
*1 Assuming comparatively short time storage, e.g., during transportation or the like.
*2 Even if the humidity is within the specified requirements, avoid such places where the inverter will be subjected to sudden
changes in temperature that will cause condensation or freezing.
Precautions for temporary storage
(1) Do not leave the inverter directly on the floor.
(2) If the environment does not satisfy the specified requirements listed in Table1.3-3 , wrap the inverter in an
airtight vinyl sheet or the like for storage.
(3) If the inverter is to be stored in a high-humidity environment, put a drying agent (such as silica gel) in the
airtight package described in (2) above.
[ 2 ] Long-term storage
The long-term storage method of the inverter varies largely according to the environment of the storage site.
General storage methods are described below.
(1) The storage site must satisfy the requirements specified for temporary storage.
However, for storage exceeding three months, the surrounding temperature range should be within the range
from -10 to +30°C (14 to 86°F). This is to prevent electrolytic capacitors in the inverter from deterioration.
(2) The package must be airtight to protect the inverter from moisture. Add a drying agent inside the package to
maintain the relative humidity inside the package within 70%.
(3) If the inverter has been installed to the equipment or panel at construction sites where it may be subjected to
humidity, dust or dirt, then temporarily remove the inverter and store it in the environment specified in Table
1.3-3.
Precautions for storage over 1 year
If the inverter has not been powered on for a long time, the property of the electrolytic capacitors may deteriorate.
Power the inverters on once a year and keep the inverters powering on for 30 to 60 minutes. Do not connect the
inverters to the load circuit (secondary side) or run the inverter.
Chapter 2 INSTALLATION AND WIRRING
2.1 Installation
(1) Installation Environment
Please install FRENIC-Ace
in locations which meet the conditions specified in “Chapter 1, 1.3.1 Usage
environment”.
(2) Installation Surface
Please install the inverter on non-combustible matter such as metals. Also, do not mount it upside down or
horizontally.
Install on non-combustible matter such as metals.
Risk of fire exists
(3) Surrounding Space
Secure the space shown in Figure 2.1-1 and Table 2.1-1. When
enclosing FRENIC-Ace
in cabinets, be sure to provide adequate board
ventilation, as the surrounding temperature may rise. Do not contain it
in small enclosures with low heat dissipation capacity.
Installation of Multiple Inverters
When installing 2 or more units in the same equipment or cabinet,
generally mount them in horizontally parallel position. When the
inverters are mounted vertically, attach partitioning boards to prevent
the heat dissipated from the lower inverter to affect the upper inverter.
For types smaller than FRN0072E2S-4
and for ambient temperature
below 40°C only, the units can be installed horizontally without any
spacing in between. (30°C or lower for HND and HHD)
Table 2.1-1 Surrounding Space (mm)
Applicable Capacity
A
B
C
FRN0059/0072E2S-4
10
0
*1FRN0085 to 0203E2S-4
50
100
100
*1 A clearance of 50 mm is required to use RJ45 connector.
C: Space in front of the inverter unit
Installation with External Cooling
The external cooling form reduces internally generated heat by
dissipating approximately 70% of the total heat generated (total heat
loss) using the cooling fins protruding outside the equipment or cabinet.
Installation with external cooling is possible for types smaller than
FRN0072E2S-4
by adding attachments (optional) for external cooling,
and for types larger than FRN0085E2S-4
by moving the mounting
bases.
(Refer to the User's Manual, Chapter 11, Section 11.15 for the outside
drawing of the external cooling attachment (optional)).
Prevent lint, wastepaper, wood shavings, dust, metal scrap, and
To install the FRN0085E2S-4
inverter with external cooling, change the mounting position of the mounting
bases following the procedure in Figure 2.1-3.
As the type and number of screws differ by inverter type, please review the following table.
For details of panel cutting size, refer to the User's Manual, Chapter 2, Section 2.3 "Attachment and Connection of
Keypad."
Table 2.1-2 Type and Number of Screws, and Tightening Torque
Inverter type
Mounting base fixation screw Case attachment screw Tightening torque (N
m)
FRN0085E2S-4
to FRN0168E2S-4
M6
20 (5 screws on top, 3
screws on bottom)
M6
20
(2 screws on top only)
5.8
FRN0203E2S-4
M6
20 (3 screws on top and
bottom each)
(3 screws on top only)
M6
12
5.8
1)
Remove all of the mounting base fixation screws and the case attachment screws on the top of the inverter.
2)
Fix the mounting bases to the case attachment screw holes using the mounting base fixation screws. A few
screws should remain after changing the position of the mounting bases.
3)
Change the position of the mounting bases on the bottom side following the procedure in 1) and 2).
Figure 2.1-3 Method to Change the Mounting Base Positions
Use the specified screws in changing the mounting bases.
Risk of fire and risk of accidents exist
Mounting base fixation screw
Mounting base (upper side)
Mounting base (lower side)
Mounting base fixation screw Case attachment screw
2.2 Wiring
2.2.1 Basic connection diagram
Standard terminal block board (with CAN) (Destinaion: -A, -E, -T and -K)
R
Ｆ
Braking resistor (option)
Direct current reactor (option) DB Ｎ(-) P(＋) P1 U V W U V W M ３～ C L1/R L2/S L3/T Magnetic contactor (MC) Circuit breaker (MCCB) or earth leakage breaker (ELCB) 400 V system 380 V to 480 V 50/60 Hz G Ground terminal (Note 2) (Note 5) (Note 6) P DB 2 1 (THR)(CM) (G) Ｎ(－) P(＋) P DB 2 1 (CM) (G) 2 1 (THR) P(+) N(-) Braking resistor (option)
Braking unit BU (option) (G) P(+) R DB (Note 7) TH1 THC PTC thermistor To [11] To [C1] (Note 13) Thermal ) R1 T1 R0 T0 (Note3) Auxiliary power input for control Auxiliary power
input for fan (Note4)
｛
(Note11) DC/DC (PLC) (FWD ) (REV ) (X1) (X2) (X3) (X4) (X5) (CM) (EN1) SINK SOURCE (EN2) 0V +24VDCRun forward command Run reverse command
Digital input 1 [SS1] Multi speed selection Digital input 2 [SS2] Multi speed selection Digital input 3 [SS4] Multi speed selection Digital input 4 [BX] Coast to a stop command Digital input 5 [RST] Alarm (error) reset Digital input common
<Y1> <Y2> <CMY> Transistor output 1 [RUN] In operation Transistor output 2 [OL] Motor overload forecast [FM] [11] 0V G E Analog output/pulse output [Fout1] Output frequency (prior to slip compensation) Data transmission and reception (RS-485) (CAN-BUS) DX+ DX-SW6 (Note12) SW1 (Note 12) (Note 8) (Note 9) Digit al inp ut Co nt ac t o ut pu t Tr ans is to r out pu t (Note 10) (Note10) Analog output common A n al og p ul se ou tp u t Transistor output common Safety signal SW5 (Note12) 30C 30B 30A Integrated alarm output (30A, 30B, 30C) 30 Current output (4(0) to 20 mA DC) Voltage output (0 to +10 V DC) Pulse output (25 to 32kp/s) (Note10)
・Power supply voltage switching connector “CN UX”
・Fan power supply connector “CN R” / “CN W” (Note10) CAN+ CAN-SW6 (Note12) RJ45 Connector (Note 9) (Note14) (PLC) Charge lamp RJ45 connector SW2 (Note 12) Opt io n co nn ec to r FMI FMV FMP FU FV FW FM (Note 13) Transformer Motor
Motor (with cooling fan)
Thermal
Data transmission and reception (RS-485)
Keypad
Detachable terminal block
Voltage input V2 (0 to +10 V DC) 〔11〕 〔12〕 〔13〕 (Note 9) +10VDC Current input C1 (4(0) to 20 mA DC) PTC thermistor input
Current input for setup
0V Analog inp ut 3 2 1 〔C1〕 (Note 9) (+) (-) Voltage input 12 (0 to +10VDC) (0 to ±10VDC) SW4 PTC AI (Note12) (Note12)SW3 C1 V2 0V Grounding terminal
Voltage input for setup
(Note15) (Note15) (Note15) U1 U2 CN UX FAN NC CN R CN W
Standard terminal block board (without CAN, with FM2) (Destinaion: -C)
R
F Braking resistor (option)
Direct current reactor (option) DB N(-) P(+) P1 U V W U V W M 3 to C L1/R L2/S L3/T Magnetic contactor (MC) Circuit breaker (MCCB) or
earth leakage breaker (ELCB) 400 V system 380 V to 480 V 50/60 Hz G Ground terminal (Note 1) (Note 2) (Note 5) (Note 6) P DB 2 1 (THR)(CM) (G) Ｎ(-) P(+) P DB 2 1 (CM) (G) 2 1 (THR) P(+) N(-) Braking resistor (option)
Braking unit BU (option) (G) P(+)R DB (Note 7) TH1 THC PTC thermistor To [11] To [C1] (Note 13) Thermal ) R1 T1 R0 T0 (Note 3)
Auxiliary power input for control Auxiliary power input
for fan (Note 4)
｛
(Note 11) DC/DC (PLC) (FWD) (REV) (X1) (X2) (X3) (X4) (X5) (CM) (EN1) SINK SOURCE (EN2) 0V +24VDCRun forward command Run reverse command
Digital input 1 [SS1] Multi speed selection Digital input 2 [SS2] Multi speed selection Digital input 3 [SS4] Multi speed selection Digital input 4 [BX] Coast to a stop command Digital input 5 [RST] Alarm (error) reset
<Y1> <Y2>
<CMY>
Transistor output 1 Transistor output 2 [OL] Motor overload forecast [FM] [11] 0V G E Analog output/pulse output [Fout1] Output frequency (prior to slip compensation) SW1 (Note 12) (Note 8) (Note 9) Di gi ta l i npu t
Digital input common
Co nt act out pu t T ra nsi st or out pu t (Note 10) (Note 10)
Analog output common
An al og p ul se ou tp ut [RUN] In operation Transistor output common Safety signal SW5 (Note 12) 30C 30B 30A Integrated alarm output (30A, 30B, 30C) 30 Current output (4(0) to 20 mA DC) Voltage output (0 to +10 V DC) Pulse output (25 to 32kp/s) ▪ Power supply voltage switching
connector “CN UX”
▪ Fan power supply connector “CN R” / “CN W” (Note 10) (Note 9) (Note 14) (PLC) Charge lamp RJ45 connector SW2 (Note 12) Op tion co nn ec to r FMI FMV FMP FU FV FW FM (Note 13) Transformer Motor Motor (with cooling fan)
Thermal
Data transmission and reception (RS-485) Keypad
Detachable terminal block
Voltage input V2 (0 to +10 V DC) [11] [12] [13] (Note 9) +10VDC Current input C1 (4(0) to 20 mA DC) PTC thermistor input
Current input for setup Voltage input for setup
0V A nal og inp ut 3 2 1 [C1] (Note 9) (+) (-) Voltage input 12 (0 to +10 V DC) (0 to ±10 V DC) SW4 PTC AI (Note 12) (Note 12)SW3 C1 V2 0V Ground terminal Data transmission and reception (RS-485) [FM2] SW7 (Note 12) FMI FMV Analog output 2 [lout] Output current (DX+) (DX-) SW6 (Note 12) (SD) (Note 9) Current output (4(0) to 20 mA DC) Voltage output (0 to +10 V DC) (Note 10) [11]
0V Analog output common
(Note 15) (Note 15) (Note 15) (Note 15) (Note 15) U1 U2 CN UX FANNC CN R CN W
(Note 1) Install recommended circuit breakers (MCCB) or residual-current-operated protective device (RCD)/
earth leakage breakers (ELCB) (with overcurrent protective function) on the inputs of each inverter
(primary side) for wiring protection. Do not use breakers which exceed the recommended rated current
.
(Note 2) Install recommended magnetic contactors (MC) as necessary on each inverter as these will be used to
disconnect the inverter from the power supply separately from the MCCB or RCD / the ELCB.
Additionally, when installing coils such as MC or solenoid close to the inverter, connect surge absorbers
in parallel.
(Note 3) When retaining the integrated alarm signal for the activation of the protective function at inverter main
power supply shut off is desired, or when continuous display of the keypad is desired, connect this
terminal to the power supply. The inverter can be operated without connecting power to this terminal.
(Note 4) The terminal does not need to be connected. Use this terminal when operating in combination with a
high power factor regenerative PWM converter (RHC series). (For types larger than FRN0203E2S-4
)
(Note 5) Remove the shorting bar between the inverter main circuit terminals P1-P(+) before connecting the
direct current reactor (DCR) (option).
ND mode: Types larger than FRN0139E2S-4
, HD/ HND mode: Types larger than FRN0168E2S-4
,
HHD mode: Always connect for FRN0203E2S-4
.
Use the direct current reactor (option) when the power supply transformer capacity is above 500 kVA
and the transformer capacity is over 10 times the rated capacity of the inverter, and when “thyristor
load exists” in the same power system.
(Note 6) Types smaller than FRN0072E2S-4
contain braking transistors, allowing direct connection of braking
resistors between P(+)-DB.
(Note 7) When connecting braking resistors to types larger than FRN0085E2S-4
, always add the braking unit
(option). Connect the braking unit (option) between P(+)-N(-). Auxiliary terminals [1] and [2] have
polarity. Please connect as shown in the diagram.
(Note 8) This terminal is used for grounding the motor. Grounding the motor using this terminal is recommended
in order to suppress inverter noise.
(Note 9) Use twisted lines or shielded lines for the control signal.
Generally, the shielded line requires grounding, but when the effect of externally induced noise is large,
connecting to [CM] may suppress the effect of noise. Separate the line from the main circuit wiring and
do not enclose in the same duct. (Separation distance of over 10 cm is recommended.) When crossing
the main circuit wiring, make the intersection perpendicular.
(Note 10) The various functions listed for terminals[X1] to [X5](digital input), terminals [Y1] to [Y2](transistor
output), and terminal [FM] (monitor output) show the functions assigned as factory default.
(Note 11) These are connectors for switching the main circuit. For details, refer to “2.2.7 Switching connector”.
(Note 12) The various switches on the control printed circuit board define the setting for the inverter operation.
For details, refer to “2.2.8 Operating various switches”.
(Note 13) Make the circuit breakers (MCCB) or the magnetic contactors (MC) trip by the thermal relay auxiliary
contacts (manual recovery).
(Note 14) Shorting bars are connected between the safety function terminals [EN1], [EN2], and [PLC] as factory
default. Remove the shorting bars when using this function.
Route the wiring following the steps below. (The inverter is already installed in the descriptions.)
2.2.2 Removal and attachment of the front cover and wiring guide
Always remove the RS-485 communication cable from the RJ-45 connector before removing the front cover.
Risk of fire and risk of accidents exist.
(1) Types smaller than FRN0072E2S-4
1) Loosen the screws of the front cover. Hold both sides of the front cover with the hands, slide the cover
downward, and pull. Then remove to the upward direction.
2) Push the wiring guide upward and pull. Let the guide slide and remove.
3) After routing the wires, attach the wiring guide and the front cover reversing the steps above.
Figure 2.2-3 Removal of the Front Cover and the Wiring Guide (for FRN0072E2S-4
)
(2) Types larger than FRN0085E2S-4
1) Loosen the screws of the front cover. Hold both sides of the front cover with the hands and slide upward to
remove.
2) After routing the wires, align the front cover top edge to the screw holes and attach the cover reversing the
steps in figure 2.2-4.
Open the keypad case to view the control printed circuit board.
Front cover attachment screw Front cover Wiring guidePush upward and pull. Let the guide slide.
Screw
Front cover
2.2.3 Precautions for wiring
Exercise caution for the following when wiring.
(1) Confirm that the supply voltage is within the input voltage range described on the rating plate.
(2) Always connect the power lines to the inverter main power input terminals L1/R, L2/S, L3/T (3 phase). (The
inverter will be damaged when power is applied while the power lines are connected to the wrong terminals.)
(3) Always route the ground line to prevent accidents such as electric shock and fire and to reduce noise.
(4) For the lines connecting to the main circuit terminals, use crimped terminals with insulating sleeves or use
crimped terminals in conjunction with insulating sleeves for high connection reliability.
(5) Separate the routing of the lines connected to the main circuit terminal input side (primary side) and the
output side (secondary side) and the lines connected to the control circuit terminals.
The control circuit terminal lines should be routed as far from the main circuit routing as possible. Malfunction
may occur due to noise.
(6) To prevent direct contact with the main circuit live sections (such as the main circuit terminal block), route the
control circuit wiring inside the inverter as bundles using cable ties.
(7) After removing the main circuit terminal screw, always restore the terminal screw in position and tighten even
if lines are not connected.
(8) The wiring guide is used to separately route the main circuit wiring and the control circuit wiring. In
FRN0072/0085E2S-4
, the main circuit wiring (lower level), the main circuit wiring (upper level) and the
control circuit wiring can be separated. Exercise caution for the order of wiring.
Case of FRN0072E2S-4
Handling the Wiring Guide
For inverter types smaller than FRN0072E2S-4
, the wiring space may become insufficient when routing the
main circuit wires, depending on the wire material used. In these cases, the relevant cut-off sections (see the
figure below) can be removed using a pair of nippers to secure routing space. Be warned that removing the wiring
guide to accommodate the enlarged main circuit wiring will result in non-conformance to IP20 standards.
After cut off
Wiring Guide (FRN0072E2S-4
)
Control circuit wiring Main circuit wiring (upper level) Wiring guide
Main circuit wiring (lower level)
Cut-off section
(8) Depending on the inverter capacity, straight routing of the main circuit wires from the main circuit terminal
block may not be possible. In these cases, route the wires as shown in the figure below and securely attach
the front cover.
2.2.4 Precautions for long wiring (between inverter and motor)
(1) When multiple motors are connected to one inverter, the wiring length is the total of all wire lengths.
(2) Precautions for high frequency leak current
When the wiring length from the inverter to the motor is long, the high frequency current may flow through
the stray capacitance between the wires with various phases. The effect may cause the inverter to become
overheated, or trip due to overcurrent. Leak current may increase and the accuracy of the displayed current
may not be ensured. Depending on the conditions, excessive leak current may damage the inverter. When
directly connecting the inverter and motor, the wiring length should be kept to below 100 meters.
To operate in excess of the above mentioned wiring length, reduce the carrier frequency or use an output
circuit filter (OFL-
-
A).
When multiple motors are operated in parallel connection configuration (group operation), and especially
when shielded cables are used in the connections, the stray capacitance to ground is large. Reduce the
carrier frequency or use output circuit filters (OFL-
-
A).
Without output circuit filter
With output circuit filter
When the output circuit filter is attached, the total wiring length should be below 100 meters (below 400
meters under V/f control).
For motors with encoders, the wiring length between the inverter and motor should be below 100 m. The
restriction comes from the encoder specification. For distances beyond 100 m, insulation converters should
be used. Please contact Fuji Electric when operating with wiring lengths beyond the upper limit.
(3) Precautions on the surge voltage when driving the inverter (especially for 400 V series motor)
When motors are driven by inverters using the PWM method, the surge voltage generated by the switching
of the inverter elements is added to the output voltage and is applied onto the motor terminals. Especially
when the motor wiring length is long, the surge voltage can cause insulation degradation in the motor.
Please perform one of the countermeasures shown below.
Use motor with insulation enhancement (Fuji’s standard motors have insulation enhancements)
Connect a surge suppression unit on the motor side (SSU50/100TA-NS)
Connect an output circuit filter (OFL-
-
A) to the inverter output side (secondary side)
Reduce the wiring length from the inverter to the motor. (Less than 10 to 20 meters)
(4) When output circuit filters are attached to the inverter or when the wiring length is long, the voltage applied
to the motor will decrease due to the voltage drop caused by the filter or wiring. In these cases, current
oscillation and lack of torque may occur due to insufficient voltage.
Power
supply Inverter Motor
Below 50 m/100 m
Power
supply Inverter Motor
Below 5 m
Output circuit filter